Ornamental paper and method of making same



Aug. 10*,1926. 1,595,207 E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed May l, 1926 6 Sheets-Sheet 1 Aug. 10 1926. 1,595,207 E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed May 1, 1926 6 Sheets-Sheet 2 Aug. 10 1926. 1,595,207

E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed May i. 1926 6 Sheets-Sheet 5 J MQ v W Aug. 10 1926. 1,595,207

E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed May ,1, 1926 6 Sheets-Sheet 4 I I Z M 6 225295 952? Aug. 10 1926. I 1,595,207 E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed y l, 1926 e sheets-sheet 5 'm'mmw" Immune! 0g i lll!l|l" Aug. 10 1926. 1,595,207

- E. MAHLER ET AL ORNAMENTAL PAPER AND METHOD OF MAKING SAME Filed May 1., 1926 6 Sheets-Sheet 6 Patented Aug. f0, 1926;

UNITED STATES, PATENT OFFICE.

ERNST MAHLER AND CHARLES G. BRIGHT, 0F NEENAH, WISCONSIN, ASSIGNOBS T0 PAPER PATENTS COMPANY, OF NEENAH, WISCONSIN, A. CORPORATION 01' WIS- oonsm'.

OBNAMENTAL PAPER AND METHOD OF MAKING SAME.

Application filed May 1,

Our invention relates to ornamental paper and the -method for the production of the same, and specifically to wall paper in which the desired effect is produced during and in the process of manufacture of the same without printing or other treatment thereof after the manufacture of the paper is completed and to a method for the production of such wall paper.

The principal object of our invention is to produce wall paper having the characteristics above set forth, and to provide animproved, efficient and practical process for. the production thereof.

Wall paper embodying our invention and constituting the novel product thereof comprises a base, preferably with a rough surface texture such as the so-called oatmeal paper, that has embodied the-rein areas of similar or different colors, and comprises also an overlayer that is to a large extent incorporated with the base and which produces a cloud effect. The paper preferably has a second coloring for producing the illusion of an irregular surface. A further object of our invention is therefore to produce a'wall paper that gives the effect of an irregular surface having color effects overlaid by a cloud effect and'in which the materials producing such effects are embodied in the paper during the manufacture and before i the completion thereof,-and to provide a method and apparatus for the production of such paper. A further object of our invention is to produce a Wall paper in whichthe application of the above mentioned second coloring is so controlled as to produce a 'sup-.

plemental design and to provide a process and apparatus for the production of such paper. A further object of our invention is- .tion may be made on existing Fourdrinier machines and a further object of our invento producea Wall paper having certain of the characteristics above described in which the color areas are in'the form of nebulous or cloud-like tints diminishing in strength 1928. Serial No. 106,139.

effects rather than being in the form of mere surface spots or stains.

The coloring of the wall paper base by means of areas of incorporated or partially submerged tints of varigated colors as contrasted with mere surface printing orstain- .ing constitutes an important feature of our invention and said effect is modified and enhanced by the cloud effect of the overlayer .by blending stock, by the second coloring that produces. the effect of an irregular surface, and also, in, a measure by the use of pulp containing coarse particles for the production of the wall paper base. The embodi ment Within the paper during its manufacture of the materials that produce the various effects therein gives to the pa er a depth not exhibited by mere. surface co oring, particularly when. the effect of an irregular surface is imparted by embodiment of the above mentioned second coloring.

In order that the overlayer of blending stock may\ be so incorporated with the base as to produce a desired cloud-like effect and the impression or illusion of depth the blending stock, in accordance with our invention, is preferably applied to the base shortly after the stock that forms the base has been deposited on the wire. The effect produced is obviously different from the of feet that would be produced by applying the tion is to provide apparatus whereby the liquid coloring that is incorporated in nebulously defined areas of the base; stock may be so controlled in its delivery to the stock as to produce the desired effect.

The second coloring is applied by a spray that projects the coloring against the incompleted paper or rather along the surface thereof in such a manner that the uneven contour or natural irregularities of the unrolled and otherwise incompleted paper determine the distribution of the color. The lights and shadows thus produced appear as such in the completed paper, and convey the illusion of a rough or uneven contour, although the paper may be actually smooth and flat. Also in accordance with our invention such application of the second coloring may be interrupted or prevented along certain lines in order to produce a further, and preferably regular, design by means of lines or areas free of the second coloring.

The effect of an irregular surface is enhanced by the fact that the blending stock is preferably white and of a heavy consistency and flows onto the base in gobs or clots thus causing the formation of miniature mountains light in COlOr incorporated with the surface of the web. The contour spray which preferably is of a rather dark tint captures or preserves this mountain effect regardless of subsequent flattening by the finishing treatment.

The various materials applied toproduce various eflects cooperate to give a final nonuniform or haphazard but nevertheless sufficiently regular appearance that has variation of color, of nebulous outline partly submerged by a cloud-like effect and having the illusion of a rough contour, the total effect being one of depth and free of definite outline and tiresome regularity.

In applying our invention to existing Fourdrinier machines, it was found that devices then available in the art for the purpose of applying liquid color in the form of drops were very unsatisfactory and generally could not be depended upon to produce uniform results of the character desired. Therefore, it became necessary to devise special color depositing apparatus, which apparatus also constitutes a rather important feature of the invention as a whole.

The article of the present invention and the method of making the same are claimed in the present application, while the apparatus for carrying out the present method and making the present article is claimed in my copending application Serial No. 98,952 filed April 1, 1926.

The apparatus which we prefer to use and which we have used successfully in practicing our invention, is disclosed in the accompanying drawings, wherein Fig.- 1 is a side elevation of the organized apparatus.

Fig. 2 is a plan view of the. same.

Fig. 3 is an elevation of the special deviclles for applying r depositing the liquid co or.

Fig. 4 is an elevation of the apparatus for applying the final spray when such is de sired.

Fig. 5 is an enlargement, partly in section, of a portion of Figure 1. I

Fig. 6 is a section taken on the line 66 of Figure 3.

Fig. 7 is an enlargement of one of the spray heads shown in Figure 4.

Fig. 8 is a section taken on the line 8-8 of Figure 7 Fig. 9 is a section taken on the line 9-9 of Figure 7 Fig. 10 is an enlargement of a portion of Figure 7, the parts being shown in section.

Fig. 11 is a section taken of the line 11-11 of Figure 10, and r Fig. 12 is an enlarged fragmentary section taken transversely across the wire at the point of application of the marking roll.

The invention is illustrated as applied to a Fourdrinier machine of the ordinary type which is equipped with the usual wire screen 20, breast roll 21 and any desired type of flow boxes 22 for delivering to the wire the main stock supply from which the base sheet is formed. One or more slices may be used. 11f the present instance, two such slices 23 and 24 of the usual design are employed. The machine is equipped with the usual suction boxes 25, 26 and 27 which, however, may be dispensed with in certain cases depending upon the particular type of paper which is being produced. Also in order to produce a finished paper of sufficient body and strength to withstand handling and facilitate application to the wall, it is preferable to duplex, that is to say, to combine the main or top sheet 28 made according to the invention with a bottom web 29 formed of ordinary stock which serves merely as a support for the topsheet. Said duplexing idea, which is extremely old in the art, obviously constitutes no part of our invention.

In order to apply the cloud forming blending stock to the surface of the inchoate web before the formation thereof is completed,

i. e. while the-.-base stock is still in a relative fiuid condition, a special form of secondary flow box and stock distributing device is used. Said blending stock preferably comprises a good grade of white sulphite stock preferably of a heavier consistency than that of the base stock and flows by gravity from the blending stock head box 30. The blend flows from head box through a pipe 31 into the secondary flow box 32 which is equipped with suitable bafiies 33 and 34 for the purpose of' effecting proper distribution and quieting of the stock. The delivery side of the flow box 32 is reduced in height and equipped with a curved apron 35 which delivers the stock in a direction towards the breast roll 21 and deposits same upon a fversely curved apron or slice 36, the edge 37 of which is as close as possible to the surface of the wire and substantially tangential thereto so that the blendin livered to the wire in a tially parallel with the surfa' e thereof.

stock distributing devices as above described, the blending stock will be evenly applied to the surface of the base, and since the flow apron 36 is located quite close to the main slice 24, the blending stock although deposited on the surface of the base sheet, will be largely incorporated with the base, although the surface will be quitemountainous or lumpy.

Describing the special devices which are employed for depositing drops of liquid color onto the base sheet intermediate the main slice 24 and the blending apron 36, it will be observed that the said color flows from four independent color supply sources so that four different colors may be employed, if desired. Hence the apparatus can be used to produce a paper having a socalled tifi'any effect. ter of convenience, the nozzles or spouts 38 leading from all of the color supply sources are located in the same line extending transversely across the machine. are supported in an apertured angle iron cross member 39 and receive their supply of liquid color from flexible tubes 40, the upper ends of which fit over the depending spouts orsmall funnels 41 suitably positioned to receive the droppings from the individual color supply nozzles as at 42.

The different colors flow from four independent supply sources and as all of said sources are similarly equipped, only one of same need be described. Referring particularly to Fig. 3, 43 indicates a sump tank for the liquid color and 44 is a small constantly driven pump, by means of which a constant supply of color from the sump tank 43 is forced up through a supply pipe 45 and into the color head box 46. A level of liquid in the head box 46 is maintained constant by means of a relatively large overflow pipe 47 which discharges downwardly into the sumptank 43.

- By means of a pipe 48, the liquid color from the head box 46 is conducted to the remote end 49 of a horizontally disposed manifoldpipe 50 which extends transversely across'the machine and directly over one of the rows of the drop guiding funnels 41.

Said manifold pipe 50 is equipped with asimilar number of drip nozzles 42 properly spaced to register said funnels 41.

As is shown best in Fig. 6, each of said drip nozzles 42 comprises an axially vertical nipple element or bleed tube 51 threaded to fit a correspondingly threaded aperture in the bottom wall of the manifold pipe 50.

stock will be deirection substam,

Preferably, as a mat- Said nozzles By means of a hexagon head 52 on the nipple 51, the latter may be adjusted in a vertical direction so that all of the nipples may be positioned in the same horizontal plane. The. actual opening in the bleed duct or opening 51 which extends vertically It will be manifest that with the blend and axially through the same is comparat'ively small in diameter and care should be taken to see that the said aperture or conduit is maintained free and unobstructed throughout its length. Also the lower end of the nipple 51 as shown at 42, should preferably be made in the form of a downward- 1y pointing cone.

1 special and, it is believed, an entirely novel arrangement is provided for the pur-" pose of maintaining a constant pressure or head at the nipples, so as to insure a sufii ciently positive and sufiiciently uniform deposit of color on the sheet. Heretofore, this has been a difficult problem. On the one hand, it has been found'impossible or not practical to use an extremely fine aperture in the drip nozzles because if made too small the apertures will clog andrefuse to function. On the other hand, if the apertures were made too large, the supply of color would be altogether too voluminous to give the required elf'ect unless the hydro static pressure at the nozzle was very, very small. To those skilled in the art, it will be obvious that the problem of maintaining a hydrostatic pressure limited in amount to an inch or so of water column while maintaining said head constant within a few per cent, is not a simple one. It has, however, been successfully solved by the use of the following described apparatus.

Referring to Fig. 3, it will be observed that to the end 53 of manifold pipe 50, there sucking action will be of a uniform amount I provided that the flow of liquid through pipes 54 and 55 is substantially constant soas to eliminate head losses due to friction.

In practice, when regulating or initially setting the head for the drip nipples, the

regulating valve 56 in the supply line 48 is adjusted to control the rate of flow of color into the manifold 50. When said valve 56 is fully open, the manifold is subjected to substantially full pressure corresponding with the elevation of liquid in the head box 46 and under this condition the barometric suction, being reduced somewhat by friction in pipes 54 and 55, is substantially less than the pressure due to the elevation of liquid in the head box 46 so that the liquid in the manifold 50 will be at a pressure substantially above that of the atmosphere. Hence, the color flows out of the manifold through the nipples 51 at a maximum rate. If less than a maximum flow out of the nozzles is required, the valve 56 is partially closed so as to reduce the flow and pressure of the liquid through pipe 48 andin manifold 50, which will incidentally reduce the flow of liquid through pipes 54 and 55. As a result there will be a reduced loss due to friction of liquid flowing through pipes 54 and 55 and the sucking action at point 53 will be correspondingly greater, thus further reducing the pressure in manifold 50. By suitably regulating the flow of liquid by valve 56*, the pressure fluidin the manifold 50 may be correspondingly regulated and such regulation can obviously be effected with extreme accuracy so as to secure any desired rate of flow out of the nipples 51.

In order to produce on such paper the H effect of high lights and shadows so as to create the illusion-of an irregular as distinguished from a plam surface, the surface of the paper may be sulnected to a spraying operation, such for example as is disclosed in the United States patent to Mahler No. 1,329,130, issued January 27, 1920. Said spraying operation is effected by means of the following improved apparatus.

Referring to Fig. 4, 57 is a sump tank for containing a supply of liquid color which, by means of a suitable constantly driven pump 58 is circulated through a head box 59. Said head box 59 supplies the spraying devices through a suitable supply line 60. Said spray heads, as shown best in Fig. 4, are disposed in a series extending across the web and preferably at a slight angle as shown in Fig. 2. The supporting devices for such spray heads preferably comprise a pair of columns 61 and 62 disposed respectively on opposite sides of the machine and connected by a transverse horizontally disposed tubular bar 63. The tops of said columns 61 and 62 are also connected by a similar transverse bar 64 which supports the liquid color manifold 65 and the air pressure manifold 66. The liquid supply manifold 65 is connected at one end with the liquid supply line and the air supply manifold 66 is supplied with air under pressure through. a suitable hose 67. The spray heads which are supported on bar 63, are adjustable thereon and to permit such adjustment the individual spray heads are connected to the manifolds and 66 by individual flexible tubes or hoses as 67 and 68.

For each spray head there is provided a split clamp '69 slidable along and rotatable around the bar 63 and capable of being locked thereon in any position by means of a suitable wing screw 70. On the side of the clamp 69 opposite to the split 71 there is a facing boss 72 to which, by suitable cap screws 73 there is bolted a main bracket 74. Said bracket 74 is fitted with a slideway' 7 5 in which there is slidably mounted a slide block 76. Said slide block 76 is drilled longitudinally and tapped to accommodate a screw 77, the ends of which are rotatably supported in lugs 78 and 79 on bracket 74. One end of the screw 77 is made with an enlarged head 80 suitably knurled to permit manual adjustment of the said screw. By means of the screw 77 the slide box 76 can be raised or lowered in the vertical slideway 75.

Said slide block 76 is formed with an enlargement 81 and is made in two pieces as shown best in Fig. 7, the two parts 82 and 83 being detachably secured together on one side by a pin 84 and on the other side by means of a swinging lock bolt 85. Said parts are separable for the purpose of admitting an annular worm gear 86 fitting within a circular recess 87 bored out in said enlargement or member 81 and undercut as shown in order to retain said gear 86 securely in said enlargement or housing 81. The housing portion 82 is equipped with a worm screw 88 having a knurled head 89, said screw 88 meshing with the worm gear 86 so that the worm 86 may be rotated within said housing 81.

The gear 86 is constructed with a laterally projecting bracket 90 having a circular extension housing as best shown in Figs. 8 and 9. Said housing 91 is made in two parts 92 and 93 normally secured together by a pin 94 on one side and a swing bolt 95 on the other side. Within said housing 91 there is rotatably mounted a worm gear 96 which may be rotated by a knurled head screw 97 which meshes with the teeth of the worm gear 96.

The worm gear 96 is drilled vertically to accommodate the air pipe 98 and-color sup ply pipe 99, vertical movement of said pipes in the gear block 96 being prevented by clamp members 100 and 101 in cooperation with a clamping screw. 102. The upper ends of the supply pipes 98 and 99 are connected to the hoses 68 and 67 by suitable unions 103 and 104 and the lower ends'of the said pipes 98 and 99 are connected to the spray head proper by means of unions 105 and 106.

Describing the spray head proper, 107 represents a yoke casting which steadies and connects the ends of the air supply nipple 108 and liquid supply nipple 109, which nipples are respectively threaded into housings 110 and 111. The housing 111 is laterally tapped to accommodate the enlarged and threaded end 112 of the small diameter tube 113 which extendsthrough the housing 1 10 and almost to the end of the outlet orifice or nozzle 114. Said nozzle 114 is tapped to fit a correspondingly threaded nose 115 on the end of housing 110, said nose 115, as indicated in Figure 11, being formed with a series of apertures 116 for conducting air into the tip of the hollow nozzle 114.

The rear end of the housing 110 is made with a neck portion 117 which is threaded to accommodate the stufiing box 118. Said stufling box 118 is equipped with a suitable flexible packing 119 which surrounds the tube or stem 113 and prevents leakage of liquid color from the spray head. I

By means of the various adjustments heretofore described, the position of the spray nozzle and the angle at which-the spray is directed against the surface of the paper may be adjusted positively and with great precision which is found to be of the greatest importance in spraying devices of this char-- acter. In order to secure the desired uni- .form effect and topreyent shading or banding, the spray nozzles should be individually adjustable otherwise lack of uniformity across the width of the paper. will inevitably result.

For the purpose of obtaining relatively simple effects by means of the spraying devices, the web may be subjected to such spray in the condition as it comes from the color dropping and blending devices without recourse to any intermediate treatment, it being understood that. the side shake is dispensed with as is described insaid Mahler patent. As distinguished from the effect produced by the Mahler patent supra, the lumps or mountains caused by the application of the blending stock result .in a pronounced accentuation of the natural roughness of the paper. Hence, the illusion of a rough contour produced by the spray is very marked, the surface of the paper having a mountainous as distinguished from a merely rough appearance. The paper retains the said markings even though it may be subsequently pressed out flat and dried in the usual way. A different effect or an effect in the form of a pattern design may be impressed upon the paper by suitably conforming the surface of the web before it passes into the zone of the spraying devices. As an example of such treatment, there is shown in Figs. 1, 2, and 12', a grooving roll 120 which is applied to the Web in the region of the suction boxes, and in the same position that would be occupied by the dandy roll in making ordinary paper.- In the present instance, such roll is shown as being constructed in the form of a cylindrical wire cage, the

wires extending circumferentially around the periphery of the roll as shown best in Fig. 12. It is not ordinarily necessary to apply any driving power to the forming roll which may be supported merely in suitable ournals on opposite sides of the machine.

By means of a forming roll such as just described, the surface of the moist web is impressed with a series of longitudinally extending grooves, the edges of which receive the impact of the spray so that the pattern of the roll is permanently shown upon the surface of the finished paper by the spray color markings.

We claim a our invention:

1. The improvement in the art of making ornamental paper on a paper making machine which consists in flowing a layer of base sheet pulp on the screen of the machine, thereafter depositing drops of liquid .color on the said layer while the latter is still in a substantially unformed or fluid condition, flowing onto the surface of the ll1-' choate sheet at a position relatively close to the forming point, a layer of blending pulp to form a cloud-like effect on said sheet,

and subsequently draining off the surplus 3. The improvement in the art-of making 1 ornamental paper on a paper making machine which consists in flowing onto the screen of the machine, a layer of base sheet forming pulp, depositing drops of liquid color on the said layer while the latter is still in a substantially unformed or fluid condition, flowng onto the surface of the inchoate sheet at a position relatively close to the forming point, a layer of blending pulp to form a cloud-like effect on said sheet, subsequently after the formation of the sheet has been substantially completed, spraying liquid color upon the rough upper surface of said sheet so as to create .the illusion of a rough contour, and thereafter pressing and drying the sheet in the usual manner.

4. The improvement in the art of making ornamental paper on a paper-making machine which consists in flowing onto the screen of the machine a layer of base sheet forming pulp, thereafter depositing dye stuifs on the said layer while ,the latter is still in a substantially unformed or fluid condition, and flowing onto the surface of the inchoate sheet a layer of blending pulp to form a cloud-like effect on said sheet, thereafter spraying liquid color on the formed sheet to create the illusion of a rough contour, and thereafter drying the. sheet.

5. The improvement in the art of making ornamental paper on a paper making machine which consists in flowing onto" the screen of the machine, a layer of base sheet forming pulp, depositing light colored blending stock on the said layer to form a rough surface efl'ect thereon, thereafter spraying liquid of a dark color at an acute angle to the horizontal, against the rough. surface of the formed sheet to capture and preserve the appearance of a rough contour, and thereafter pressing and drying the sheet.

6. The improvement in the art of making ornamental paper on a paper making machine which consists in flowing a layer of base sheet pulp on the screen of the machine, thereafter flowing onto the surface of the inchoate sheet, a layer of thick blendingpulpto form a cloud-like mountainous effect on said sheet, thereafter spraying liquid of contrasting color against the sides of said mountains to capture the mountainous efi'ect regardless of any subsequent fiattening of the sheet, subsequently draining off the surplus Water to complete the formation of the sheet, and thereafter drying the sheet.

7 The improvement in the art of making ornamental paper on a paper making machine which consists in flowing onto the screen of the machine, a layer of base sheet forming pulp, thereafter flowing onto the surface of the inchoate sheet, a layer of heavy white blending pulp to form a mountainous clouddike eifect on said sheet, subsequently after the formation ofthe sheet has been substantially completed, spraying liquid of a dark color at an angle against the sides only of said mountains so as to capture and preserve the appearance of a rough contour, and thereafter pressing and drying the sheet.

8. An ornamental paper, comprising a base having a relatively coarse surface texture, color incorporated with and dif portion of said base, deposits of blending 'stock also incorporated withthe face portion of the base and partially enclouding the face of said base, and color distributed on said deposits to create the illusion of a rough contour.

9. An ornamental paper having a flat surface, and including a base in the form of a rough unfinished or inchoate web of sheet pulp having incorporated therein drops of liquid color while the base is in an unformed or fluid condition forming patches or irregular areas of diffused and shaded color, a layer of blending stock incorporated in the surface of the base and of contrasting color so distributed as to produce a cloud 0r mottled effect, and a second coloring so distributed over the color patches and layer of blending stock as to produce the illusion of a rough contour.

10. An ornamental paper having a substantially flat surface and comprising a base layer and cloud-like surface deposits incorporated with-the base layer and correspondingly shaded on one side only with relatively darked coloring material to produce the appearance of being in relief.

11. An ornamental paper having a substantially fiat surface and comprising a base layer and cloud-like surface deposits incor porated with the base layer and correspondingly shaded on one side only with a relatively different coloring material to produce the appearance of being in relief.

12. 1. n ornamental paper having a substantially fiat surface and comprising a base layer, and irregular surface deposits of relatively light colored blending stock overlying and partially incorporated with the base layer and producing the eflect of clouds thereon, the flanks of the said clouds on one side only having a relatively dark coloring material distributed thereover so as to cause said clouds to present to the eye the illusion of being in relief.

ERNST MAHLER. CHARLES o. BRIGHT.

fused through localized areas of the face ts 

